[svsantosh]

dhanush these are from d x dot com

lots of fun stuff avbl there, mohan gopal had ordered it, I think they are around 450 for both. that site ships to your doorstep but takes around 3 weeks from china.

[svsantosh]

In a recent Ooty Vacation trip I had lot of misfire issues up in the hills. Ooty is not so elevated above MSL like himlayas, but I had a tough time with the blue/white smoke, pat-put-pat misfire under accelaration after gear change, the smoke reeking of diesel smell!!

Oh - And the early morning cold starting trouble had me at wits end!! Damn bugger just wouldnt start - and once it started entire hotel parking lot was covered in white smoke!! Took at least 15 heaters and 25 crank attempts!! And this was in outside temp at 15+ degrees, I would have junked the AG had it been in himalayas @ Zero deg!

What is causing all this, is it weak compression due to worn out rings (severe back compression) or a bad FIP setting/health.

PS - Once I hit mettupalayam, 30+degrees, it runs smooth as butter, today morning @ 7AM it started in 1 heater+crank - absolutely no smoke and diesel smell issues!

[dhanushs]

Originally Posted by svsantosh

Took at least 15 heaters and 25 crank attempts!!

On the whole, looks like a weak engine symptom. However, Re: Above symptom.. Ooty aint that cold, so, are you sure if all the glow plugs are working?

[svsantosh]

yep engine is sure weak!! Smokes from the top (oil filler) more than the ooty steam engine, but regd plugs - why no such issue in hosur or blore? Hosur aint that cold, but still its dips to 20 in night and I start daily @ 7AM in 1 htr/crk cycle.

PS - whats the best way to know if the plugs are working? And how to check how old they are?

[svsantosh]

Engine opened up for a complete rebuild. After lots of phone calls, emails, PMs, to all near and dear and unknown, decided to rebuild the O.E XD3P for one time - live with it for next year or two, then go with the tide!

PS - also got rid of the used army sand grips for 4 JK Elanzo's from a scorpio that upgraded after delivery from showroom. Better ride quality and braking immediately.

[dhanushs]

Originally Posted by svsantosh

Engine opened up for a complete rebuild. After lots of phone calls, emails, PMs, to all near and dear and unknown, decided to rebuild the O.E XD3P for one time - live with it for next year or two, then go with the tide!

Will be keeping a very very keen eye on this rebuild!

Where are you getting the job done?

[svsantosh]

I think I know why, your XD is giving sleepless nights eh?!

Just bcoz I didnt have 1L (upto 1.2L) for a DiTurbo engine mod (without GB swap), I am forced to rebuild my XD3P for around 45K (as quoted by my mech).

Place - where else! after knowing for him for 3 years at a very personal level, it had to be my Hosur mech (Babu & his boyz). He has quoted max 45K including travel in a hired Sumo to carry the head, block and pump/nozzle to Salem and back in a days time. None of the lathe jobs in blore and hosur appeal to my mech, who am I to ask! And he has assured this quote included all OE M&M parts and not a level down, but I wouldnt know the diff, its trust!

He did mention if I know anyone in chennai who can approach the Lucas TVS company authorized center for the pump/nozzle rebuild, he says it makes a big diff between a chennai and salem job, but I dont know much in chennai market.

I wish the AC system wasnt drained out, but couldnt avoid. So while I am at it, opening up the dash to access the OE blower and getting it cleaned out for better cooling.

[ArunV]

So it is 45K huh? and how long does it take to complete the work?

[svsantosh]

Originally Posted by ArunV

So it is 45K huh? and how long does it take to complete the work?

Block, head and FIP will be loaded onto sumo by tonight and by tommorow morning work will start in Salem on all 3. It will return by late night back to hosur and assembly will start friday morning. If given 100% attention, by friday night the engine will be assembled and ready on the table for a saturday morning fit and saturday eve start.

PS, a pic from today morning.

[dhanushs]

Originally Posted by svsantosh

I think I know why, your XD is giving sleepless nights eh?!

Right now, its sorted out temporally, I think!

Just bcoz I didnt have 1L (upto 1.2L) for a DiTurbo engine mod (without GB swap)

Did you call the guy that I mentioned? He had quoted a ~70k for a properly working Di Turbo.

And he has assured this quote included all OE M&M parts and not a level down, but I wouldnt know the diff, its trust!

Well, you could personally buy and give him the parts. I guess its pretty cheap in Coimbatore.

[svsantosh]

1) yeah, the labor and additional changes like radiator mods, etc shoot up and mainly the need for a diff GB put me off. BA10 'may' fail with a Di or a Diturbo and I cant go the whole mile now!

2) I know these guys' mentality, even if I miss 1 washer they will say engine seized bcoz of that, rather give the whole contract and hold them responsible in case it fails; Of course, rationally speaking.

I understand they make at least 2-4K extra by taking up a end to end job, but I get to save my time which is kinda short now.

[svsantosh]

Couple of updates

1) Looked at the connecting rod bush and confirmed it was a factory sealed engine (till yesterday) and its OE size parts all around, no oversizing done "till date".

2) Sudarshan - the cam shaft had 1 burr mark on one of the pushrod points (elliptical part, what do you call it?) - confirmed with mech that even the OHC will be polished.

3) Clutch friction plate is slightly worn out (asymmetrically) abnormal wear out due causing jerks! will be replaced, pressure plate (cover assy looks good, so leaving it for now).

4) Starter motor bendix slightly worn out on edges (was experiencing grr-grr cranks at times, anyways getting the whole lucas starter serviced)

5) Acid washing the radiator (not overhauling it) since it was rebuilt last year (less than 5K Kms ago), acid washing to remove any leftover salts from engine block.

6) Front prop shaft fouled with bell crank even with the NGCS special (extra bump stop) above the front diff!!

[Rajith]

hi,

After Rebuilding XD3P, no owner seems 100% happy, except Mechanics,Lathewalas and supporting guys.

Its a great engine when its new.

For a 4wd applications DI / DIT engines will be right choice for a longer wheel base machines.

[svsantosh]

Right, let me share my experiences too here. I wasnt left with much of a choice, even if this lasts a year I can think about other options. But again, I dont expect to do too much offroad this AG, lets see.

[dhanushs]

^^ For ON-Road use, there should be absolutely no problem, and will last you a long time. The issue starts when the gear is LOW and rpm is in redline.